Pile fabric floor covering



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Oct. l2, 1954 .F p GROAT 2,691,390

PILE FABRIC FLOOR COVERING Filed Nov. 2. 1949 HTTONEY.

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Patented Oct. 12, 1954 PILE FABRIC FLOOR COVERING Francis P. Groat, Bloomsburg, Pa., assgnor to The Magee Carpet Company, Bloomsburg, Pa., a corporation of Pennsylvania Application November 2, 1949, Serial No. 124,963

1 Claim. l

This invention relates to improvements in woven pile fabrics, such as carpets and rugs, and the method of weaving the saine. More particularly the invention relates to a pile fabric having the pile formed of curled pile yarns arranged in groups and spaced apart in a weftwise and warpwise direction with the curled pile overlying the spaces devoid of pile to produce a high pile texture at a relative low cost.

A further object of the invention resides in making a pile fabric having two or more twist pile warps in every other dent which are raised and cut to form a plurality of curled pile yarns between every other pair of weft threads to produce a fabric with a high pile texture.

A still further object of the invention resides in making a pile fabric in which the groups of curled pile yarns are separated from each other in a weftwise direction by stuffer warps and separated in a warpwise direction by weft threads, the spacing being such that the curled yarns completely overlie and cover the spaces devoid of pile.

Other objects and advantages of the invention will be apparent during the course of the following description.

In the accompanying drawing forming a part of this specification and in which like numerals are employed to designate like parts throughout the same,

Fig. 1 is an exploded perspective view of the new fabric, and,

Fig. 2 is a plan View of the pattern showing the arrangement of the curled pile.

Referring to the drawing, the backing of the fabric may be of any suitable constructiony but in the form illustrated includes stuffer warps 5 and two series of weft threads and 'l lying, respectively, above and below the 'stuffer warps and bound in place by crossed binding warps B and 9. Twist pile warps il] extend warpwise of the fabric between the upper and lower series of weft threads. There are two or more pile warps l0 in every other warpwise dent of stuifer warps 5, the pile warps being disposed above stuffer warps which are not shown in the drawing for the sake of clearness. The dents between the sets of pile warps have stuifer warps only which space the sets of pile warps apart.

The pile warps It are hard twist yarns of conventional construction, the strands being tightly twisted about 7 turns to one inch and the twist is set by the action of the hot water in the dye bath. When these yarns are woven over pile wires and then cut, the legs of the loops contract in the direction of their length forming curled legs.

The fabric is woven on a conventional Wilton loom having the wire mechanism adjusted so that a wire is inserted between every other pair of upper weft threads. There are two pile warps in every other dent and these are raised to form a shed. A conventional cutting wire is then inserted in the shed of pile warps and the warps are returned to the backing of the fabric forming rows of loops on the wires. After the desired number of wires are inserted they are successively withdrawn cutting the loops formed thereon. As the loops are cut the legs contract in the direction of their length, due to the twist of the yarn, forming curled tuft legs. Owing to the fact there are two pile warps in a single dent, with pile warps in every other dent only, the loops formed on the wire will be arranged in spaced groups of two loops which when cut form a plurality of curled tuft legs that spread over and cover the intervening spaces between the groups of tuft legs.

A fabric woven in the manner described will have rows of curled pile arranged in groups of four curls, each group being spaced apart from adjacent groups in both a warpwise and weftwise direction. In Fig. 2 a pattern of the fabric is shown wherein XX represents the two pile warps in each dent with a dent or space devoid of pile warps therebetween. 'The stuffer warps serve as spacing means between warpwise rows of pile and twoweft threads space the weftwise rows apart. These spaces devoid of pile are completely covered by the curls of yarn so that the fabric has a uniform high pile surface of -attractive appearance. While only -two pile warps are shown in a single warpwise course it is to be understood two or more pile warps may be used in a single dent.

Having thus described my invention, I claim:

A pile fabric comprising a backing composed of upper and lower weft threads with stuffer warps extending in a straight plane between the upper and lower weft threads held in place by crossed binder threads above and below the weft threads, and sets of twist pile warp-s lying below the upper weft threads in spaced apart relation having portions raised between every other pair of upper weft threads and cut to provide a group of more than two contracted tuft legs, each 3 group of tuft legs being sufcently spaced in a warpwse and weftwse direction and the twist of said legs being such as to cause them to spread outwardly and commngle with the legs of adjacent groups.

References Cited in the le of this patent UNITED STATES PATENTS Number Name Date 1,749,551 Stroud Mar. 4, 1930 1,816,574 Foster et al July 28, 1931 Number Number lo 691,288 772,888

Name Date Andreae Nov. 2, 1932 Barrett Feb. 18, 1935 Clark Mar. 9, 1948 Jackson Apr. 11, 1950 Jackson May 30, 1950 Clark Dec. 11, 1951 FOREIGN PATENTS Country Date France July 8, 1939 France Aug. 20, 1934 

